On-machine tool measurement (OMTM) is an emerging technique that can automatically measure cutting tool diameter and length in the machining process with a laser tool setter on the machine table. Tool condition monitoring (TCM) is to measure the width of the flank wear land as tool wear and detect tool failure during machining. Unfortunately, no TCM technique has been developed, tool wear cannot be detected, and tool failure cannot be predicted in machining. It is in high demand that tool wear is measured and compensated, and tools are replaced right before they fail. However, different types of tools wear in different pattern;​ measuring the tool diameter at a height with OMM cannot well represent tool wear, not even to predict tool failure. To realize TCM with the OMM technique, this research proposes a new approach to predicting a reamer’s life so that the reamer can be changed before it fails. It he relationship between tool wear and tool failure has not been thoroughly investigated, especially since there are various cutting tool types, each with its unique failure mode, which means different tool types require specific methods for evaluating tool failure based on wear detection through TCM. This research propose an approach to predicting the tool life of reamer, a type of metal cutting tool, in hole machining. The study begins by examining the geometry of reamers and the cutting principles underlying the reaming process. This analysis aids in investigating the relationship between the geometric changes in reamers resulting from wear and the occurrence of reamer failure.

Additionally, the research extensively explores the main forms of reamer wear and carefully examines their impact on the quality of hole reaming. A comprehensive understanding of these wear forms is crucial for accurately predicting tool life. Moreover, a selection of reamer geometries has been identified, directly influencing the quality of reaming operations. The corresponding effective dimensional tolerances for these geometries are also determined.

This research successfully develops the fusion technology of On-Machine Monitoring (OMM) and Tool Condition Monitoring (TCM), which enables real-time tool wear assessment and facilitates timely maintenance interventions. The proposed approach has notable benefits for the manufacturing industry, including enhanced production efficiency, reduced downtime, and improved machining quality. The findings of this research contribute to advancing reamer tool life prediction methodologies and hold practical implications for optimizing manufacturing processes. The advanced OMM-TCM fusion technology is a valuable tool for ensuring efficient and reliable hole-reaming operations, benefiting the whole manufacturing industry.